Samson 2404-2 Mounting And Operating Instructions Download Page 2 | Manualshive

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could result in death or serious injury

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Note

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EB 2540 EN

Note on these mounting and operating instructions

These mounting and operating instructions assist you in mounting and operating the device
safely. The instructions are binding for handling SAMSON devices. The images shown in
these instructions are for illustration purposes only. The actual product may vary.

Î

For the safe and proper use of these instructions, read them carefully and keep them for
later reference.

Î

If you have any questions about these instructions, contact SAMSON‘s After-sales Service
([email protected]).

The mounting and operating instructions for the devices are included
in the scope of delivery. The latest documentation is available on our
website at

www.samsongroup.com > Service & Support > Downloads >

Documentation

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Summary of Contents for 2404-2

Page 1: ...Translation of original instructions EB 2540 EN Type 2404 2 Excess Pressure Valve with Pilot Valve Self operated regulator for small set point ranges Edition May 2023...

Page 2: ...and operating the device safely The instructions are binding for handling SAMSON devices The images shown in these instructions are for illustration purposes only The actual product may vary For the...

Page 3: ...3 3 Type 2420 Actuator 2 5 2 3 4 Type 2406 Pilot Valve 2 5 2 3 5 Type 2441 Input Pressure Regulator 2 5 3 Design and principle of operation 3 1 3 1 Additional fittings 3 3 3 2 Technical data 3 4 4 Sh...

Page 4: ...regulator after service work 9 3 9 3 Service work 9 3 9 4 Ordering spare parts and operating supplies 9 4 10 Decommissioning 10 1 11 Removal 11 1 11 1 Removing the regulator from the pipeline 11 1 11...

Page 5: ...AMSON SAMSON does not assume any liability for damage resulting from the failure to use the de vice for its intended purpose or for damage caused by external forces or any other external factors Refer...

Page 6: ...e plant operators and operating personnel must prevent hazards that could be caused in the regulator by the process medium the operating pressure or by moving parts by taking appropriate precautions P...

Page 7: ...uct defined in the technical data are observed This also applies to the start up and shutdown procedures Start up and shutdown procedures fall within the scope of the operator s duties and as such are...

Page 8: ...s pressure gauges etc 1 1 Notes on possible severe personal injury DANGER Risk of bursting in pressure equipment Regulators and pipelines are pressure equipment Impermissible pressure or improper open...

Page 9: ...incorrect nameplates or labels Risk of burn injuries due to hot or cold components and pipelines Depending on the process medium regulator components and pipelines may get very hot or cold and cause b...

Page 10: ...lid particles in the pipeline The plant operator is responsible for cleaning the pipelines in the plant Flush the pipelines before start up Risk of regulator damage due to the use of unsuitable lubric...

Page 11: ...required to work on the regulator Only use tools approved by SAMSON When in doubt consult SAMSON Risk of the process medium being contaminated through the use of unsuitable lubri cants and or contamin...

Page 12: ...1 8 EB 2540 EN Safety instructions and measures...

Page 13: ...point range 7 Valve size 8 Pressure rating 9 Perm differential pressure 10 Perm temperature 11 Body material 12 Serial number if applicable 13 T V registration no if exists 14 Data Matrix code 15 CE m...

Page 14: ...e at actuator 7 Valve size 9 Set point range 10 Diaphragm material 11 Country of origin 12 UKCA if applicable 13 Year of manufacture 14 Month of manufacture 15 CE marking 1 Max perm operating pressure...

Page 15: ...nufacture 4 Type designation 5 Thread size valve size DIN DN ANSI NPS JIS DN A B 6 Flow coefficient DIN KVS ANSI CV JIS CV 7 Perm temperature DIN C ANSI F JIS C F 8 Set point range DIN bar ANSI psi JI...

Page 16: ...ation of the nameplates Location of the nameplate on the main valves Location of the nameplate on the input pressure regulator Location of the nameplate on the pilot valve Fig 2 5 Nameplates of the ma...

Page 17: ...etails on the nameplate see sec tion 2 1 2 3 3 Type 2420 Actuator Specifying the material number you can contact us to find out which material is used It is specified on the nameplate in the MNo field...

Page 18: ...2 6 EB 2540 EN Markings on the device...

Page 19: ...valve over the control line 2 4 The force created by the upstream pressure p1 at the operating diaphragm 2 2 is compared with the adjusted spring force of the set point spring The pilot valve opens wh...

Page 20: ...ing 1 2 Operating diaphragm main valve 2 Pilot valve 2 1 Set point spring 2 2 Operating diaphragm pilot valve 2 3 Set point adjuster screw SW 27 11 8 2 4 Control line 2 5 Cap 3 Input pressure regulato...

Page 21: ...the regula tor Do not use the strainer to permanently filter the process medium Select a strainer mesh size suitable for the process medium Any impurities carried along by the process medium may impa...

Page 22: ...pressure to an adjusted set point For gases Medium temperature range 5 to 195 F 20 to 90 C Set points 0 075 to 3 psi 5 to 200 mbar Valve sizes NPS 2 to 16 DN 65 to 400 Pressure rating Class 125 150 3...

Page 23: ...differential pressure p 175 psi 12 bar Perm temperature 5 to 195 F 20 to 90 C 1 Conformity Type 2422 as main valve balanced by a diaphragm with Type 2420 Actuator Valve size NPS 8 DN 200 NPS 10 DN 250...

Page 24: ...si 25 to 60 mbar 0 75 to 3 psi 50 to 200 mbar Actuator area 100 in 640 cm 50 in 320 cm 50 in 320 cm 50 in 320 cm Input pressure pe Fixed setting by input pressure regulator min 15 psi 1 bar Perm tempe...

Page 25: ...el body Actuator springs 1 4310 3 Type 2422 Valve main valve with Type 2420 Actuator Body A126B A216 WCC A351 CF8M EN GJL 250 1 0619 1 4408 Valve seat and plug NPS 8 to 10 DN 200 to 250 CF3M 1 4409 NP...

Page 26: ...ns for sour gas service NACE possible Table 3 6 Materials for input pressure regulator Material numbers according to ASTM and DIN EN Input pressure regulator Type 2441 Body 1 4408 A351 CF8M Valve seat...

Page 27: ...2 5 317 mm L3 approx 9 4 240 mm 8 3 212 mm D 5 to 15 mbar 0 075 to 0 2 psi 15 380 mm A 100 in 640 cm 10 to 30 mbar 0 15 to 0 45 psi 11 2 285 mm A 50 in 320 cm 25 to 60 mbar 0 35 to 1 5 psi 11 2 285 mm...

Page 28: ...12 3 313 mm 13 5 343 mm D 0 075 to 0 2 psi 5 to 15 mbar 15 380 mm A 100 in 640 cm 0 15 to 0 45 psi 10 to 30 mbar 11 2 285 mm A 50 in 320 cm 0 35 to 1 5 psi 25 to 60 mbar 11 2 285 mm A 50 in 320 cm 0...

Page 29: ...d principle of operation D H H3 B L3 L1 L2 Pipe Supply pressure p Pipe Control line for upstream pressure p1 Pipe Supply pressure p Dimensions Fig 3 3 DN 65 to 100 NPS 2 to 4 Versions with seal diaphr...

Page 30: ...gn and principle of operation H3 H L1 D L3 L2 Pipe Supply pressure p Pipe Supply pressure p Pipe Control line for upstream pressure p1 Dimensions Fig 3 4 DN 125 to 150 NPS 6 Versions with seal diaphra...

Page 31: ...esign and principle of operation H3 H L1 D L3 L2 Pipe Supply pressure p Pipe Control line for upstream pressure p1 Pipe Supply pressure p Dimensions Fig 3 5 DN 125 to 150 NPS 6 Versions with seal diap...

Page 32: ...tion D H H3 B L3 L1 L2 Dimensions Pipe Supply pressure p Pipe Control line for upstream pressure p1 Pipe Supply pressure p Pipe Control line for upstream pressure p1 Fig 3 6 DN 200 to 400 NPS 8 to 16...

Page 33: ...ration H H3 B D L3 L1 L2 Pipe Supply pressure p Pipe Control line for upstream pressure p1 Pipe Supply pressure p Pipe Control line for upstream pressure p1 Dimensions Fig 3 7 DN 200 to 300 NPS 8 to 1...

Page 34: ...3 16 EB 2540 EN Design and principle of operation...

Page 35: ...e weight and dimensions of the units to be lifted and transported in order to select the appropriate lifting equipment and lifting accessories Refer to the transport documents and the De sign and prin...

Page 36: ...15 to max 55 kg taking into account age gender and physical fitness Observe the occupational health and safety regulations valid in the country of use DANGER WARNING WARNING Risk of personal injury d...

Page 37: ...ing work for longer periods of time Make sure that the axis of the pipeline is always horizontal during lifting and the axis of the plug stem is always vertical Lifting 1 Attach one sling to the flang...

Page 38: ...gs Repair any damage immediately Protect the regulator against moisture and dirt Store it at a relative humidity of less than 75 In damp spaces prevent condensation If necessary use a drying agent or...

Page 39: ...shorter than the recommended lengths To ensure that the regulator functions proper ly proceed as follows Install the regulator allowing sufficient space to remove the actuator and valve or to perform...

Page 40: ...nting position the valve actuator and pipeline must be supported or suspended Note Do not attach supports directly to the valve actuator or control line NOTICE 4 3 4 4 4 3 1 2 4 1 4 2 Tank 1 Shut off...

Page 41: ...ady during installation work Flush the pipeline before installing the regulator The plant operator is responsible for cleaning the pipelines in the plant Check any mounted pressure gauges to make sure...

Page 42: ...the valve The arrow on the valve indicates the direction of flow 5 Make sure that the correct flange gaskets are used 6 Bolt the pipe to the valve free of stress 7 Fasten the supply line pipe to the i...

Page 43: ...ions Wear hearing protection when working near the regulator DANGER DANGER WARNING Risk of burn injuries due to hot or very cold components and pipelines Depending on the process medium valve componen...

Page 44: ...tor components If necessary shut off the control lines on performing a pressure test on the main valve Make sure that the pressure rises simulta neously upstream and downstream of the regulator to avo...

Page 45: ...ur during operation caused by the process medium and the operating condi tions Wear hearing protection when working near the valve WARNING WARNING WARNING Re Risk of personal injury due to process me...

Page 46: ...m up to reach ambient temperature before start up 2 Slowly open the shut off valve in the sup ply pipeline Slowly opening these valves prevents a sudden surge in pressure and high flow velocities whic...

Page 47: ...perating condi tions Wear hearing protection when working near the valve WARNING WARNING WARNING 7 1 Adjusting the set point Adjust the set point by tensioning the set point springs 2 1 at the set poi...

Page 48: ...e will even remain stuck in the closed position 3 Monitor the set point pressure to be ad justed at the pressure gauge on the up stream pressure side When the upstream pressure reaches the set point p...

Page 49: ...m of the main valve defective Replace the balancing diaphragm with a new one Install a shut off valve instead of the pilot valve If the main valve does not open when the shut off valve is opened the m...

Page 50: ...le Raise upstream pressure or reduce downstream pressure Set point range of the pilot valve is too low Convert or replace pilot valve Main valve seized up Clean main valve Install a shut off valve ins...

Page 51: ...S CV coefficient Periodic excitation to vibrate originating from the plant Contact SAMSON Possibly change the natural frequency e g over a needle valve when there is resonance in the plant Contact SAM...

Page 52: ...event of a regulator malfunction 1 Close the shut off valves to stop the pro cess medium from flowing through the regulator 2 Perform troubleshooting see sec tion 8 1 3 Rectify those malfunctions that...

Page 53: ...u ries Allow components and pipelines to cool down or warm up to the ambient tem perature Wear protective clothing and safety gloves WARNING Risk of personal injury due to residual pro cess medium in...

Page 54: ...se original spare parts by SAMSON which comply with the original specifications SAMSON s After sales Service can support you in drawing up an inspection and test plan for your plant Note Tip 9 1 Prepa...

Page 55: ...ure the re quirements and conditions for start up or putting the valve back into operation are met 9 3 Service work Before performing any service work preparations must be made to the regu lator see s...

Page 56: ...ON s After sales Service for infor mation on spare parts lubricants and tools Spare parts Contact SAMSON s After sales Service for more information on spare parts Lubricants Contact SAMSON s After sal...

Page 57: ...ponents and the pipeline may become very hot or cold Risk of burn inju ries Allow components and pipelines to cool down or warm up to the ambient tem perature Wear protective clothing and safety glove...

Page 58: ...r for service work or disassembly proceed as follows 1 Close the shut off valve 1 2 Depressurize the plant 3 Completely drain the pipelines and valve 4 If necessary allow the pipeline and reg ulator c...

Page 59: ...medium can escape and depending on its properties may lead to personal in jury e g chemical burns Wear protective clothing safety gloves and eye protection Before removing the valve make sure the fol...

Page 60: ...11 2 EB 2540 EN...

Page 61: ...vices can be returned to SAMSON for repair Proceed as follows to return devices 1 Put the regulator out of operation see the Decommissioning section 2 Decontaminate the valve Remove any residual proce...

Page 62: ...12 2 EB 2540 EN...

Page 63: ...on al refuse regulations Do not dispose of components lubricants and hazardous substances together with your other household waste We can provide you with a recycling passport according to PAS 1049 on...

Page 64: ...13 2 EB 2540 EN...

Page 65: ...0 EN 14 1 Certificates 14 Certificates The EU declarations of conformity are in cluded on the next pages EU declaration of conformity in compli ance with Pressure Equipment Directive 2014 68 EU on pag...

Page 66: ...CF8M NPS 1 2 Class 150 all fluids Control valve 3214 DIN EN body EN GJL 250 DN 65 125 PN 16 fluids G2 L2 L11 DIN EN body EN GJS 400 18 LT DN 50 80 PN 25 fluids G2 L2 L11 ANSI body A126 B NPS 3 4 Clas...

Page 67: ...0 all fluids 42 2421 RS DIN EN body 1 0619 1 4408 1 4571 and 1 4401 1 4404 DN 32 50 PN 16 all fluids DIN EN body 1 0619 1 4408 1 4571 and 1 4401 1 4404 DN 32 40 PN 25 all fluids ANSI body A216 WCC A35...

Page 68: ...of the laws of the Member States relating to the making available on the market of pressure equipment 2014 68 EU of 15 May 2014 Applied conformity assessment procedure for fluids according to Article...

Page 69: ...y EN GJS 400 18 LT DN 100 150 PN 25 fluids G2 L2 L11 DIN EN body 1 0619 and 1 4408 DN 65 250 PN 16 all fluids DIN EN body 1 0619 and 1 4408 DN 50 250 PN 25 all fluids DIN EN body 1 0619 and 1 4408 DN...

Page 70: ...PN 40 all fluids ANSI body A126 B NPS 6 16 Class 125 fluids G2 L2 L11 ANSI body A216 WCC und A351 CF8M NPS 2 16 Class 150 all fluids ANSI body A216 WCC und A351 CF8M NPS 2 10 Class 300 all fluids 2331...

Page 71: ...the European Parliament and of the Council on the harmonization of the laws of the Member States relating to the making available on the market of pressure equipment 2014 68 EU of 15 May 2014 Applied...

Page 72: ...14 8 EB 2540 EN...

Page 73: ...SAMSON s After sales Service can support you concerning lubricants and sealants ap proved by SAMSON 15 3 Tools SAMSON s After sales Service can support you concerning tools approved by SAMSON 15 4 Ac...

Page 74: ...be found on our website u www samsongroup com or in all SAMSON product catalogs Required specifications Please submit the following details Device type Type and nominal size of the main valve pilot v...

Page 75: ......

Page 76: ...2023 05 09 English SAMSON AKTIENGESELLSCHAFT Weism llerstra e 3 60314 Frankfurt am Main Germany Phone 49 69 4009 0 Fax 49 69 4009 1507 samson samsongroup com www samsongroup com EB 2540 EN EB 2540 EN...

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